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DOE OSTI2022

Strain Gauge Diagnostic Development for use in Vessel Health Monitoring for Hydro-shots

Six-foot vessels are a crucial component to protecting high fidelity equipment at DARHT. Analysis shows these vessels have a limited life span (~10 shots) due to fatigue, ratcheting, and damage accumulation. Vessel health monitoring and diagnostics can help inform decision on a vessel’s fitness for service. Strain gauges are an easy and effective sensor for use in vessel health monitoring. In early March, J-2 executed a qualification shot, uniform blast loading with minimal fragments, with bi-axial strain gauges fielded at four locations around vessel. Several damage features were extracted from the data, and frequency content helps to validate computer modelling of the vessel response. Permanent plastic strain at each location was significant with location one having the most strain at the end state, with 230 micro-strain. However, residual pressure in the vessel could be a major factor in this strain. PEEQ is a measure of total plastic equivalent strain accumulation. The equivalent strain at location one exceeded the plastic strain limit four times and accumulated the most PEEQ with 2036 micro-strain. As expected, this qualification shot did contribute to damage in the vessel, and should be considered in its fitness for service, but not critical enough to pull it from service. Frequency content also gave valuable information on the modal response of the vessel and contributes to the understanding of how the vessel responds to the initial blast load with an expected lower frequency membrane/breathing mode and transitioning to higher frequency bending modes in the vessel wall.

42 ENGINEERING↗
DOE OSTI2025

EGS Collab Experiment 2: Continuous Active Source Seismic Monitoring (CASSM)

The dataset contains continuous active-source seismic monitoring (CASSM) data collected during EGS Collab Experiment 2, conducted from February to September 2022 at the Sanford Underground Research Facility in Lead, South Dakota. This experiment aimed to investigate enhanced geothermal systems through high-pressure fluid injections at depths of 1200-1500 meters. The seismic monitoring system included 16 three-component piezoelectric accelerometers and 24 hydrophones installed in boreholes around the injection zones, recording signals from piezoelectric seismic sources. Data were acquired using both continuous and triggered recording systems, with sampling rates of up to 100 kHz. The raw data are organized by timestamps and stored in .dat format, with accompanying log files. Calibration certificates for selected accelerometers are provided to aid in correcting sensor responses, though users are advised to consider possible effects of enclosures and installation on sensor performance. Users are strongly advised to consult the accompanying report, which outlines the experimental setup, data acquisition, sensor specifications, and recording systems.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Westinghouse Accident Tolerant Fuel Phase 2B with Higher Enriched and Higher Burnup Add-On Project Final Technical Report Deliverable Volume 1

The Westinghouse Electric Company LLC (Westinghouse) accident tolerant fuel (ATF) program funded by Westinghouse and the US Department of Energy (DOE) utilized chromium (Cr) coated zirconium alloy cladding with doped UO 2 (ADOPT(TM)) and uranium silicide (U 3 Si 2 ) high density/high thermal conductivity fuel for its lead test rod (LTR) program with irradiation beginning in 2019. ADOPT is a Cr 2 O 3 +Al 2 O 3 doped UO 2 pellet with increased oxidation resistance and density, and increased resistance to fission gas release. Due to the issues with U 3 Si 2 fuel reaction in pressurized water reactor (PWR) environments, uranium nitride (U 15 N) has been substituted for U 3 Si 2 as a long-term fuel option. Cr coated cladding with ADOPT fuel is the near-term Westinghouse EnCore fuel product. The long-term EnCore ® fuel product is SiGA ® SiC/SiC composite cladding with high density/high thermal conductivity UN fuel. In 2020, the higher burnup and higher enriched and (HBHE) program was integrated into the ATF program. The objective of this expanded program is to extend ATF burnups to at least 75 MWd/kgU to economically facilitate 24-month cycles in PWRs. The ATF program now includes ADOPT fuel with enrichments >5% 235 U. Over the past several years, Westinghouse has tested the Cr coated zirconium (Zr) and silicon carbide (SiC) claddings in Westinghouse Churchill autoclaves and the Massachusetts Institute of Technology (MIT) reactor. Additionally, the Cr coated cladding has been tested in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) and in LTR programs at the Doel 4 and Bryon 2 commercial reactors. High temperature tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried out to determine the time and temperature limits for the Cr coated zirconium claddings. These tests indicate that Cr coated Zr cladding can take temperatures up to about 1500°C for short periods of time without becoming totally oxidized. The main issue is the formation of the Cr-Zr eutectic at 1333°C resulting in the migration of this eutectic inward with the formation of ZrCr 2 which rapidly oxidizes to ZrO 2 on the outside of the tube. The Cr coated Zr cladding also delays the bursting of the tube, reduces the burst area, and reduces hydriding and embrittlement of the Zr which is a major benefit for reducing fuel fragmentation, redistribution, and dispersal (FFRD), the major licensing issue faced by HBHE. The manufacturing parameters for the SiC have been found to have a significant effect on the corrosion rate of the SiC in light water reactor (LWR) conditions and significant improvements have been made in the yield, quality, and oxidation resistance of the SiC cladding by identifying and tightening manufacturing process parameters. Current autoclave results for SiC composite claddings indicate that a corrosion rate of fewer than 2 micrometers per year can be achieved which meets corrosion requirements under normal operating conditions. High temperature steam oxidation tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried and determined that SiC cladding can withstand temperatures up to about 1800°C to 1900°C before excessive corrosion reactions begin, and that the SiC will not balloon and burst. ADOPT fuel pellets were incorporated into the Westinghouse ATF program because of their increased density and oxidation resistance. A topical report supporting the use of ADOPT pellets has been submitted to the NRC and will be approved shortly. ADOPT pellets have been a product in Europe for over 15 years. The additives work to make larger grain sizes which appear to reduce fission gas release during transients as well as increase the density of the pellet. Fuel rod and assembly design in preparation for the lead test rod (LTR) and lead test assembly (LTA) programs is underway as well as licensing efforts with the Nuclear Regulatory Commission (NRC). Finally, accident analyses coupled with economic evaluations for both operating savings as well as fuel savings have been initiated. Modular Accident Analysis Program 5 (MAAP5) calculations indicate that both Cr coated cladding and SiC composite cladding can increase the time to fuel rod loss of geometry for up to two hours longer than current Zr based cladding in a station blackout scenario. This additional time is due to the much higher oxidation resistance of the SiC and Cr coated cladding. These two hours can be used to implement additional response options instituted through the Diverse and Flexible Mitigation Capability (FLEX) program by reactor operators. Both ATF cladding options also reduce hydrogen production which dramatically reduces primary system and containment pressure and the risk of fission product release beyond containment in the unlikely event of an accident. The lower pressure in the system allows more time to feed cooling water to the core, resulting in the avoidance of fuel melting. The coping time is extended indefinitely if the modest water flow provided by FLEX continues. Experimental work on methods to rapidly fabricate SiC composite structures with high density and reduce the fabrication price of SiC fibers while maintaining a high level of performance is needed. Methods for mitigating or stopping the Cr-Zr eutectic are also needed to further improve the oxidation resistance of Cr coated Zr. Minimal (<1%) swelling of U 3 Si 2 and subsequent fission gas release has been demonstrated up to 20 MWd/kgU. Irradiation experiments with U 3 Si 2 fuel in ATR to determine these properties at 40 MWd/kgU were completed but post irradiation examinations were not done since U 3 Si 2 has been replaced by UN. UN has three issues that are being addressed. The first is increasing the oxidation resistance so that there is not excessive reaction up to ~1500°C. While UN increases the pellet density and additives to the UN postponed the temperature at which rapid oxidation occurred by ~100°C to 200°C, this is not enough, and pellet coating options are now being pursued. The second is developing a method to manufacture that does not require the multi-step process of UF 6 to UO 2 to UC to UN. Efforts are underway looking at UF 6 to UN 2 to UN and UF 6 to UF 4 to UN 2 to UN reactions. Finally, an economically acceptable process for potentially enriching the 15 N content of the nitrogen used to make UN to >95% 15N was identified though not experimentally validated. In addition to the work supported by the DOE, research and testing activities are being carried on in a world-wide effort funded by many countries such as Sweden, United Kingdom, Belgium, Netherlands, Spain, Germany, Japan, and France. This work is being facilitated through the Westinghouse led Collaboration for Advanced Research on Accident Tolerant Fuel (CARAT) program. Annual meetings were organized in 2018 and 2019 by Westinghouse as a venue for presentation of this work and to provide for the cross-fertilization of ideas among the many outstanding researchers in the ATF area. No meetings were held in 2020 and 2021 due to the COVID-19 related restrictions on traveling and gatherings. Since SiC, coated cladding, and high-density fuel options are not currently used in the nuclear industry; support from the government and industry members is needed to further the significant effort of setting new standards. The same is true for the Nuclear Regulatory Commission (NRC) which must review and approve the commercial use of these new fuels since all current regulations are oriented toward Zr/UO 2 fuel. Several meetings have been held with the NRC to generate a fast-track approach to licensing ATF using a combination of atomic modeling, in-rod sensors, and in-reactor testing. This approach was memorialized in an “Accelerated Fuel Qualification White Paper” prepared by the Accelerated Fuel Qualification Working Group lead by General Atomics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Westinghouse Accident Tolerant Fuel Phase 2B with Higher Enriched and Higher Burnup Add-On Project Final Technical Report Deliverable Volume 2

The Westinghouse Electric Company LLC (Westinghouse) accident tolerant fuel (ATF) program funded by Westinghouse and the US Department of Energy (DOE) utilized chromium (Cr) coated zirconium alloy cladding with doped UO 2 (ADOPT(TM)) and uranium silicide (U 3 Si 2 ) high density/high thermal conductivity fuel for its lead test rod (LTR) program with irradiation beginning in 2019. ADOPT is a Cr 2 O 3 +Al 2 O 3 doped UO 2 pellet with increased oxidation resistance and density, and increased resistance to fission gas release. Due to the issues with U 3 Si 2 fuel reaction in pressurized water reactor (PWR) environments, uranium nitride (U 15 N) has been substituted for U 3 Si 2 as a long-term fuel option. Cr coated cladding with ADOPT fuel is the near-term Westinghouse EnCore ® fuel product. The long-term EnCore fuel product is SiGA ® SiC/SiC composite cladding with high density/high thermal conductivity UN fuel. In 2020, the higher burnup and higher enriched and (HBHE) program was integrated into the ATF program. The objective of this expanded program is to extend ATF burnups to at least 75 MWd/kgU to economically facilitate 24-month cycles in PWRs. The ATF program now includes ADOPT fuel with enrichments >5% 235 U. Over the past several years, Westinghouse has tested the Cr coated zirconium (Zr) and silicon carbide (SiC) claddings in Westinghouse Churchill autoclaves and the Massachusetts Institute of Technology (MIT) reactor. Additionally, the Cr coated cladding has been tested in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) and in LTR programs at the Doel 4 and Bryon 2 commercial reactors. High temperature tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried out to determine the time and temperature limits for the Cr coated zirconium claddings. These tests indicate that Cr coated Zr cladding can take temperatures up to about 1500°C for short periods of time without becoming totally oxidized. The main issue is the formation of the Cr-Zr eutectic at 1333°C resulting in the migration of this eutectic inward with the formation of ZrCr 2 which rapidly oxidizes to ZrO 2 on the outside of the tube. The Cr coated Zr cladding also delays the bursting of the tube, reduces the burst area, and reduces hydriding and embrittlement of the Zr which is a major benefit for reducing fuel fragmentation, redistribution, and dispersal (FFRD), the major licensing issue faced by HBHE. The manufacturing parameters for the SiC have been found to have a significant effect on the corrosion rate of the SiC in light water reactor (LWR) conditions and significant improvements have been made in the yield, quality, and oxidation resistance of the SiC cladding by identifying and tightening manufacturing process parameters. Current autoclave results for SiC composite claddings indicate that a corrosion rate of fewer than 2 micrometers per year can be achieved which meets corrosion requirements under normal operating conditions. High temperature steam oxidation tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried and determined that SiC cladding can withstand temperatures up to about 1800°C to 1900°C before excessive corrosion reactions begin, and that the SiC will not balloon and burst. ADOPT fuel pellets were incorporated into the Westinghouse ATF program because of their increased density and oxidation resistance. A topical report supporting the use of ADOPT pellets has been submitted to the NRC and will be approved shortly. ADOPT pellets have been a product in Europe for over 15 years. The additives work to make larger grain sizes which appear to reduce fission gas release during transients as well as increase the density of the pellet. Fuel rod and assembly design in preparation for the lead test rod (LTR) and lead test assembly (LTA) programs is underway as well as licensing efforts with the Nuclear Regulatory Commission (NRC). Finally, accident analyses coupled with economic evaluations for both operating savings as well as fuel savings have been initiated. Modular Accident Analysis Program 5 (MAAP5) calculations indicate that both Cr coated cladding and SiC composite cladding can increase the time to fuel rod loss of geometry for up to two hours longer than current Zr based cladding in a station blackout scenario. This additional time is due to the much higher oxidation resistance of the SiC and Cr coated cladding. These two hours can be used to implement additional response options instituted through the Diverse and Flexible Mitigation Capability (FLEX) program by reactor operators. Both ATF cladding options also reduce hydrogen production which dramatically reduces primary system and containment pressure and the risk of fission product release beyond containment in the unlikely event of an accident. The lower pressure in the system allows more time to feed cooling water to the core, resulting in the avoidance of fuel melting. The coping time is extended indefinitely if the modest water flow provided by FLEX continues. Experimental work on methods to rapidly fabricate SiC composite structures with high density and reduce the fabrication price of SiC fibers while maintaining a high level of performance is needed. Methods for mitigating or stopping the Cr-Zr eutectic are also needed to further improve the oxidation resistance of Cr coated Zr. Minimal (<1%) swelling of U 3 Si 2 and subsequent fission gas release has been demonstrated up to 20 MWd/kgU. Irradiation experiments with U 3 Si 2 fuel in ATR to determine these properties at 40 MWd/kgU were completed but post irradiation examinations were not done since U 3 Si 2 has been replaced by UN. UN has three issues that are being addressed. The first is increasing the oxidation resistance so that there is not excessive reaction up to ~1500°C. While UN increases the pellet density and additives to the UN postponed the temperature at which rapid oxidation occurred by ~100°C to 200°C, this is not enough, and pellet coating options are now being pursued. The second is developing a method to manufacture that does not require the multi-step process of UF 6 to UO 2 to UC to UN. Efforts are underway looking at UF 6 to UN 2 to UN and UF 6 to UF 4 to UN 2 to UN reactions. Finally, an economically acceptable process for potentially enriching the 15 N content of the nitrogen used to make UN to >95% 15 N was identified though not experimentally validated. In addition to the work supported by the DOE, research and testing activities are being carried on in a world-wide effort funded by many countries such as Sweden, United Kingdom, Belgium, Netherlands, Spain, Germany, Japan, and France. This work is being facilitated through the Westinghouse led Collaboration for Advanced Research on Accident Tolerant Fuel (CARAT) program. Annual meetings were organized in 2018 and 2019 by Westinghouse as a venue for presentation of this work and to provide for the cross-fertilization of ideas among the many outstanding researchers in the ATF area. No meetings were held in 2020 and 2021 due to the COVID-19 related restrictions on traveling and gatherings. Since SiC, coated cladding, and high-density fuel options are not currently used in the nuclear industry; support from the government and industry members is needed to further the significant effort of setting new standards. The same is true for the Nuclear Regulatory Commission (NRC) which must review and approve the commercial use of these new fuels since all current regulations are oriented toward Zr/UO 2 fuel. Several meetings have been held with the NRC to generate a fast-track approach to licensing ATF using a combination of atomic modeling, in-rod sensors, and in-reactor testing. This approach was memorialized in an “Accelerated Fuel Qualification White Paper” prepared by the Accelerated Fuel Qualification Working Group lead by General Atomics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Physics-informed State-space Neural Networks for transport phenomena

This work introduces Physics -informed State -space neural network Models (PSMs), a novel solution to achieving real-time optimization, flexibility, and fault tolerance in autonomous systems, particularly in transportdominated systems such as chemical, biomedical, and power plants. Traditional data -driven methods fall short due to a lack of physical constraints like mass conservation; PSMs address this issue by training deep neural networks with sensor data and physics -informing using components' Partial Differential Equations (PDEs), resulting in a physics -constrained, end -to -end differentiable forward dynamics model. Further, through two in silico experiments - a heated channel and a cooling system loop - we demonstrate that PSMs offer a more accurate approach than a purely data -driven model. In the former experiment, PSMs demonstrated significantly lower average root -mean -square errors across test datasets compared to a purely data -driven neural network, with reductions of 44 %, 48 %, and 94 % in predicting pressure, velocity, and temperature, respectively. Beyond accuracy, PSMs demonstrate a compelling multitask capability, making them highly versatile. In this work, we showcase two: supervisory control of a nonlinear system through a sequentially updated state -space representation and the proposal of a diagnostic algorithm using residuals from each of the PDEs. The former demonstrates PSMs' ability to handle constant and time -dependent constraints, while the latter illustrates their value in system diagnostics and fault detection.

42 ENGINEERING↗
DOE OSTI2021

Effects of Inlet Area Ratio on Operability of an Axial Air Inlet Rotating Detonation Combustor

This research presents the first results from a new Rotating Detonation Combustor (RDC) design with an axial air inlet and rear-facing angled fuel injection. This design features a variable air inlet that allows for the study of the effect of inlet area ratio on operation and to directly study the coupling between the air plenum and channel of the RDC while minimizing inlet pressure losses. This device maintains the same downstream channel configuration as those previously tested in our laboratory, which includes a 154 mm outer channel diameter and a constant area channel with a width of 7.6 mm. All tests were completed with a downstream hydrogen-air afterburner capable of flashing back in the channel to initiate detonation operation. Initial tests demonstrated successful operation at air mass flow rates from 160 to 770 g/s and equivalence ratios from 0.53 to 1.05 at multiple air inlet to channel area ratios, indicated that sensors installed within the air feed plenum are able to characterize the dynamic characteristics of waves within the detonation channel, and verified that the design goals for this configuration were achieved.

Shepard, Joshua↗
DOE OSTI2025

Predicting Initial Trans-Membrane Pressure for Optimized Operations in UF Unit Using Random Forest

With the growing scarcity of freshwater, innovative process design mechanisms like Reverse Osmosis (RO) are increasingly gaining attention among water treatment utilities to address the rising demand. Ensuring reliable water production necessitates efficient resource utilization, minimizing downtime in (ultra-filtration) UF systems. Recent advancements in machine learning (ML) have enabled the development of accurate data-driven models for Model Predictive Control (MPC), often requiring minimal prior knowledge of underlying physical processes. In this study, we present predictive regression models based on Random Forest (RF) and Auto-Regressive (AR) approaches to forecast the initial Trans-Membrane Pressure (TMP) for each filtration cycle in data generated by Direct Potable Reuse (DPR) systems. The proposed RF-based model demonstrates superior performance compared to baseline methods, including historical mean, Last Observation Carried Forward (LOCF), and naïve AR models, across various forecasting horizons in terms of root mean square error (RMSE) metric. To evaluate how different classes of process variables contribute to TMP dynamics over time, we examine the feature importance of independent covariates across multiple forecast horizons. This analysis provides insight into the temporal relevance of operational and sensor-derived features, guiding control and monitoring strategies. Additionally, the impact of hyperparameter tuning on TMP prediction performance is studied for both direct and recursive RF modelling approaches across increasing forecast horizons. Accurate prediction of initial TMP is critical for optimizing RO operations, as it enables the development of robust modelling frameworks by accurately estimating membrane fouling trends, thereby enhancing process efficiency and long-term reliability. The demonstrated efficacy of the RF-based approach highlights its potential as a tool for real-time decision-making in water treatment systems, paving the way for advanced process optimization and sustainable water resource management.

Mukherjee, Subrata [ORNL] (ORCID:0000000309930338)↗
DOE OSTI2021

Inference of Induced Fracture Geometries Using Fiber-Optic Distributed Strain Sensing in Hydraulic Fracture Test Site 2

Fiber-optic Distributed Strain Sensor observations in a vertical well allow rapid inference of the time evolution of nearby hydraulic fracture heights and their vertical aperture distributions during stimulation and depressurization. We describe a computationally efficient deconvolutional model based on an elastostatic kernel for fracture opening within an isotropic, homogeneous, linear elastic medium. Furthermore, an application of this model to observations from the Hydraulic Fracture Test Site 2 reveals that ultimate fracture heights are typically greater than those indicated by microseismic monitoring, and some hydraulic fractures continue their upward growth for several hours after high-pressure injections ceased.

58 GEOSCIENCES↗
DOE OSTI2020

Analysis of Microseismicity and Reactivated Fault Size to Assess the Potential for Felt Events by CO 2 Injection in the Illinois Basin

The results of monitoring of carbon dioxide (CO 2 ) injection at the Illinois Basin—Decatur Project (IBDP) and the companion Illinois Industrial Carbon Capture and Sequestration Sources (IL-ICCS) project—have shown that reservoir response to fluid pressure changes can vary significantly at different injection locations within the same reservoir. Predrill reservoir characterization is important to identify potentially seismogenic faults. However, interpretations of newly reprocessed 3D seismic reflection data illustrate the challenges related to their identification in a region dominated by faulting with small vertical offsets. Faults interpreted in the 3D seismic volume range from ~300 to 1200 m wide and are in the same size range as faults that could have been the source of historical events up to Mw 2.7 in central Illinois. The array of monitoring sensors that was installed for the IBDP continues to collect data, as injection operates in IL-ICCS, the second injection well. CO 2 injection rates for the IL-ICCS well are on average 1.7 times the rates injected in the IBDP well, but a significantly reduced rate of induced seismicity is observed. This article presents results of passive seismic monitoring for the duration of the project to date, integrating active and passive seismic data to develop a new interpretation of the subsurface structure at the Decatur site that explicitly identifies pathways for fluid flow into the basement leading to induced seismicity, and provides a geological explanation for the sharp reduction of induced seismicity during injection at higher rates into the second well. The use of seismic moment to estimate the length of seismogenic slip planes in the local subsurface suggests that faults large enough to produce felt seismicity are unlikely to be present at or near the Decatur site.

Geochemistry & Geophysics↗
DOE OSTI2024

Fluorescence imaging of individual ions and molecules in pressurized noble gases for barium tagging in 136Xe

Abstract The imaging of individual Ba 2+ ions in high pressure xenon gas is one possible way to attain background-free sensitivity to neutrinoless double beta decay and hence establish the Majorana nature of the neutrino. In this paper we demonstrate selective single Ba 2+ ion imaging inside a high-pressure xenon gas environment. Ba 2+ ions chelated with molecular chemosensors are resolved at the gas-solid interface using a diffraction-limited imaging system with scan area of 1 × 1 cm 2 located inside 10 bar of xenon gas. This form of microscopy represents key ingredient in the development of barium tagging for neutrinoless double beta decay searches in 136 Xe. This also provides a new tool for studying the photophysics of fluorescent molecules and chemosensors at the solid-gas interface to enable bottom-up design of catalysts and sensors.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

The EGS Collab Project: Learnings from Experiment 1

The primary objective of the EGS Collab Project sponsored by DOE is to increase the understanding needed to efficiently implement enhanced geothermal systems (EGS). One goal of the EGS Collab project is to create a collaborative research environment in which to study stimulation of crystalline rock at the 10 meter scale. Key to this effort is the collection of high quality data to allow comparison to numerical coupled process models in an effort to build confidence in the codes and modeling techniques used. In response to this, the EGS Collab team has created an underground test bed at the Sanford Underground Research Facility (SURF) in Lead SD at a depth of approximately 1.5 km to examine hydraulic fracturing (Experiment 1). We are currently designing a second test bed aimed at investigating shear stimulation (Experiment 2). At the Experiment 1 location, we have characterized our host rock using laboratory testing and numerous field-based geophysical and geological techniques, and created a well-instrumented test bed to allow us to carefully monitor stimulation events and flow tests. In addition to the installed geophysical sensors, we have used tracer tests, differences in the ambient microbial communities at flow collection locations, and cold water injection to inform us about dynamic flow pathways. In Experiment 1, we have hydraulically stimulated the host rock in a number times at several locations in one well, creating new fractures that connect to existing fractures between the injection and production boreholes. We have performed long-term ambient and chilled water injection tests as an analog to EGS, and have monitored system changes resulting from these water injections through geophysical monitoring, flow and pressure measurements, tracer tests, and microbiology. Here, we summarize the tests performed, issues identified including poroelastic and thermoelastic effects, Joule-Thomson effects, restarting effects, indications of flow channeling, and the primary learnings from Experiment 1.

Enhanced Geothermal Systems, EGS Collab, stimulati↗
DOE OSTI2025

Autonomous Aerosol and Plasma Co‐Jet Printing of Metallic Devices at Ambient Temperature

Abstract Additive manufacturing of metallic materials holds the potential to revolutionize the fabrication of functional devices unattainable via traditional methods. Despite recent advancements, printing metallic materials typically requires thermal processing at elevated temperatures to form dense structures with desired properties, which presents a major challenge for direct printing and integration with temperature‐sensitive materials. Herein, a unique co‐jet printing (CJP) method is reported integrating an aerosol jet and a non‐thermal, atmospheric pressure plasma jet to enable concurrent aerosol deposition of metal nanoparticle inks and in situ sintering at ambient temperature. A machine learning algorithm is integrated with the CJP to perform real‐time defect detection and autonomous correction, enhancing the yield of printed films with high electrical conductivity from 44% to 94%. Concurrent printing and sintering eliminate the need for post‐printing processing, reducing the overall manufacturing time by multiple folds depending on product size. CJP enables direct printing of functional devices on a variety of temperature‐sensitive materials including biological materials. Direct printing of hydration sensors on living plant leaves is demonstrated for long‐duration monitoring of hydration level in the plant. The versatile CJP method opens tremendous opportunities to harmoniously integrate abiotic and biotic materials for emerging applications in wearable/implantable devices and biohybrid systems.

Du, Yipu [Department of Aerospace and Mechanical E↗
DOE OSTI2026

The NEXT-100 Detector

The NEXT collaboration is dedicated to the study of double beta decays of 136 Xe using a high-pressure gas electroluminescent time projection chamber. This advanced technology combines exceptional energy resolution (≤ 1% FWHM at the Q ββ value of the neutrinoless double beta decay) and powerful topological event discrimination. Building on the achievements of the NEXT-White detector, the NEXT-100 detector started taking data at the Laboratorio Subterráneo de Canfranc (LSC) in May of 2024. Designed to operate with xenon gas at 13.5 bar, NEXT-100 consists of a time projection chamber where the energy and the spatial pattern of the ionising particles in the detector are precisely retrieved using two sensor planes (one with photo-multiplier tubes and the other with silicon photo-multipliers). The detector has been operating at stable conditions using argon and xenon gases at ~4 bar and drift fields of 74 V cm –1 and 118 V cm –1 , respectively. Alpha decays from the 222 Rn chain have been used to test and monitor the stability of the detector, showing a constant electron lifetime in the drift volume. In this paper, in addition to reporting the results of the commissioning run, we provide a detailed description of the NEXT-100 detector, describe its assembly, and present the current estimation of the radiopurity budget.

Adams, C. [Argonne National Laboratory; NVIDIA] (O↗
DOE OSTI2025

A device for volatile organic compound (VOC) analysis from skin using heated dynamic headspace sampling

Abstract Human skin is an important source of volatile organic compounds (VOCs) offering noninvasive methods to gain clinical metabolite information. This work was focused on the development of a skin sampling device based on a dynamic headspace sampling method with the addition of temperature to increase VOC metabolite recovery. The device preconcentrates skin VOC emissions onto a sorbent substrate, which can either be preserved for offline analysis or attached to a real time sensor downstream. In this work, skin VOC samples were analyzed offline using thermal desorption-gas chromatography-mass spectrometry. A list of 10 common skin VOCs was pre-selected to optimize parameters of sampling time, sampling temperature, and sorbent selection. Overall, this study highlights an effective skin VOC sampling technology with a heating dimension (40 °C, rather than 30 °C or no heating) with a sampling time of 15 min (rather than 5 or 30 mins) and onto Tenax TA sorbent (rather than PDMS), which collectively increases the recovery of compounds with lower vapor pressure and decreases the observed variability in skin VOC measurements. Finally, a list of 79 skin VOC compounds were detected and identified within a cohort of 20 young, healthy volunteers.

Biochemistry & Molecular Biology↗
DOE OSTI2024

Flow Sensor Test Article (F-STAr) - Water Testing and Commissioning Report for FY2024

Argonne National Laboratory’s Mechanism Engineering Test Loop (METL) facility is developing new experimental testing capabilities with the Flow Sensor Test Article (F-STAr). F-STAr’s mission is to provide high flowrate, sodium submersible testing capabilities to support the development of sodium cooled nuclear fission reactors. Figure 1 shows a model of F-STAr (left) and a photo of the partially assembled test article (right) with several of the main components labeled. The system currently includes a large pump with desired flowrates of up to 100 GPM; an immersion heater with a maximum power of 5 kW; an immersion cooler with an estimated maximum cooling power of 2 kW; and an experimental test section to support sub-test articles. Initially, F-STAr will be setup for testing flow sensors, specifically Eddy Current Flow Sensors (ECFS). However, the system can be reconfigured to support a wide range of testing needs. For example, F-STAr could be setup to complete testing of hydraulic components, heat exchangers, hydrodynamic bearings, seals, and more. This report will provide an update on the development of F-STAr with a focus on the water testing and commissioning activities during Fiscal Year 2024 (FY24). First, the report will focus on describing the pump development. Specifically, updates will be provided on troubleshooting the pump’s excessive vibrational issues. In addition to updates on the pump, pressure-flowrate performance testing in water will be described. Furthermore, updates will be provided on a pump shaft bushing development as well as rigging procedures. Future work and paths forward for F-STAr will be described. Finally, a short summary on the ECFS development will be described at the end of the report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Microfluidic Fabrication Techniques for High-Pressure Testing of Microscale Supercritical CO 2 Foam Transport in Fractured Unconventional Reservoirs

Pressure limitations of many microfluidic platforms have been a significant challenge in microfluidic experimental studies of fractured media. As a result, these platforms have not been fully exploited for direct observation of high-pressure transport in fractures. This work introduces microfluidic platforms that enable direct observation of multiphase flow in devices featuring surrogate permeable media and fractured systems. Such platforms provide a pathway to address important and timely questions such as those related to CO 2 capture, utilization and storage. This work provides a detailed description of the fabrication techniques and an experimental setup that may serve to analyze the behavior of supercritical CO 2 (scCO 2 ) foam, its structure and stability. Such studies provide important insights regarding enhanced oil recovery processes and the role of hydraulic fractures in resource recovery from unconventional reservoirs. This work presents a comparative study of microfluidic devices developed using two different techniques: photolithography/wet-etching/ thermal-bonding versus Selective Laser-induced Etching. Both techniques result in devices that are chemically and physically resistant and tolerant of high pressure and temperature conditions that correspond to subsurface systems of interest. Both techniques provide pathways to high-precision etched microchannels and capable lab-on-chip devices. Photolithography/wet-etching, however, enables fabrication of complex channel networks with complex geometries, which would be a challenging task for laser etching techniques. This work summarizes a step-by-step photolithography, wet-etching and glass thermal-bonding protocol and, presents representative observations of foam transport with relevance to oil recovery from unconventional tight and shale formations. In conclusion, this work describes the use of a high resolution monochromatic sensor to observe scCO 2 foam behavior where the entirety of the permeable medium is observed simultaneously while preserving the resolution needed to resolve features as small as 10 μm.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Measurement of particulated matter (PM1, PM2.5, PM10) using a PM sensor during the SAIL campaign in Gothic, CO and Mt. Crested Butte, CO

We deployed another PM sensor (Modulair-PM, QuantAQ) to measure the mass concentration of particulate matter (PM) for three size cuts at both the main site (M1) and supplementary site (S2) of the SAIL from 14 June 2022 to 14 June 2023. The instruments provide the mass concentration of PM1, PM2.5 and PM10. Mass concentrations were calculated based on measurements made with a nephelometer and an OPC. We used Quant-AQ's algorithm [please see their documentation here and the references within] to determine the mass concentrations reported. Here, we present the time series of sample relative humidity, temperature, pressure, and the mass concentration of PM1, PM2.5 and PM10. We also present the size distribution of the aerosol particles within a diameter range of 0.35 - 40 micron, measured by the OPC of the pm-modulair. However, we encourage caution while using the size distribution data, since it is operated only with the factory calibration. Abstract and description of the campaign can be found here : https://www.arm.gov/research/campaigns/amf2022ssb.

54 ENVIRONMENTAL SCIENCES↗